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2004 SUBARU IMPREZA WRX STI Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Chassis Code: GDB Engine Code: EJ257 Generation Generation Designation: Second Generation (GDB) Generation Years: 2002-2007 Codes Vin Drivetrain Code: H (for AWD) 👋 Introduction Market Position Performance Segment: Compact Performance Sedan/Wagon Rally Heritage: Directly influenced by Subaru's World Rally Championship (WRC) success Competitive Analysis Key Competitors: Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf R Key Features Drivetrain Philosophy: Symmetrical All-Wheel Drive (AWD) system with Driver Controlled Center Differential (DCCD) Engine Philosophy: Performance-tuned turbocharged Boxer engine Suspension Tuning: Performance-oriented suspension setup for enhanced handling Braking System: Upgraded Brembo braking system for superior stopping power 📋 Manual Details Coverage Areas Coverage Scope: Complete vehicle service and repair Engine Coverage: All engines (specifically EJ257 for WRX STI) Drivetrain Coverage: All-Wheel Drive (AWD) system, differentials, transmission Body Coverage: Exterior panels, interior trim, chassis components Electrical Coverage: Wiring diagrams, component testing, ECU diagnostics Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Official Service and Repair Manual Language Language: English Format Format: PDF File Type: Digital (Searchable PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine teardown, assembly, cylinder head, pistons, crankshaft, lubrication, cooling Engine Management: Fuel injection, ignition system, emissions control, ECU diagnostics, sensors Transmission: 6-speed manual transmission (TY756VW4CA), clutch system, driveline components Suspension: Front struts, rear multi-link, springs, shocks, anti-roll bars, alignment procedures Brakes: Front Brembo 4-piston calipers, rear 2-piston calipers, ABS system, brake fluid Steering: Power assisted rack and pinion, steering column Electrical System: Starting and charging system, lighting, instrumentation, audio system, power windows, airbags HVAC: Air conditioning, heating, ventilation, refrigerant handling Body And Chassis: Frame, body panels, doors, hood, trunk, glass, interior trim Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection Troubleshooting: Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting Repair And Rebuild: Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly Diagnostics: OBD-II diagnostics, sensor testing, actuator testing, ECU relearning procedures Specifications And Tolerances: Torque specifications, measurement tolerances, clearances Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Technical Depth Depth Level: Comprehensive (from basic maintenance to full engine/transmission rebuilds) Diagnostic Capability: Advanced diagnostic procedures, component-level testing Wiring Detail: Pinouts, wire colors, connector diagrams 📊 Manual Specifications File Format File Format Type: PDF (Portable Document Format) Searchability: Text-searchable, allowing quick access to specific information Printability: Printable pages for workshop use Digital Features: Hyperlinked sections for easy navigation (typical for professional PDFs) Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Horizontally-opposed turbocharged Boxer 4-cylinder Displacement: 2.0 Liters (1994 cc) Bore X Stroke: 92.0 mm x 75.0 mm Compression Ratio: 8.4:1 Valve Train: DOHC, 16 valves (4 valves per cylinder) Performance Horsepower: 300 hp @ 6000 rpm (SAE Net) Torque: 290 lb-ft @ 4000 rpm (SAE Net) Fuel System Fuel Delivery: Sequential multi-port fuel injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Turbocharger: IHI VF30 (or similar, depending on market) Intercooler: Top-mounted air-to-air intercooler 🔧 Transmission Standard Transmission Type: 6-speed manual Transmission Model: TY756VW4CA Optional Optional Transmission: N/A (6-speed manual was standard on WRX STI) Features Dccd: Driver Controlled Center Differential (DCCD) with automatic and manual modes Differential Type: Front: Helical LSD; Rear: Active Torque Split DCCD with Viscous LSD 📐 Dimensions Exterior Length: 4415 mm (173.8 inches) Width: 1770 mm (69.7 inches) Height: 1440 mm (56.7 inches) Wheelbase: 2625 mm (103.3 inches) Front Track: 1515 mm (59.6 inches) Rear Track: 1505 mm (59.3 inches) Weights Curb Weight: Approx. 1460 kg (3219 lbs) Gross Vehicle Weight Rating: Approx. 1900 kg (4189 lbs) Cargo Trunk Volume: Approx. 0.33 m³ (11.8 cu ft) (Sedan) 🛡️ Safety Features Ratings NHTSA Front Crash Test: 4/5 Stars (Driver/Passenger) NHTSA Side Impact Test: 4/5 Stars (Front/Rear Passenger) IIHS Moderate Overlap Front: Good Active Features ABS: 4-wheel Anti-lock Braking System (ABS) E Brake Force Distribution: Electronic Brake-force Distribution (EBD) Traction Control: Standard Traction Control System (TCS) Passive Features Airbags: Front driver and passenger airbags, front side-impact airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system 💡 Technology Features Infotainment Head Unit: Factory-installed CD player with AM/FM radio. Higher trims may have premium audio systems. Speaker System: Standard 4-speaker or optional 6-speaker audio system (e.g., Clarion). Driver Assistance Cruise Control: Standard electronic cruise control Anti Theft System: Factory immobilizer and alarm system Connectivity Auxiliary Input: Optional or aftermarket auxiliary input for audio devices 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (severe conditions), or 7,500 miles or 12 months (normal conditions) Air Filter Replacement Interval: Every 15,000-30,000 miles, or as needed based on inspection Cabin Air Filter Replacement Interval: Every 15,000-30,000 miles, or annually...
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2004 SUBARU IMPREZA WRX STI Service & Repair Manual-PDF
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Chassis Code:
GDB
Engine Code:
EJ257
Generation
Generation Designation:
Second Generation (GDB)
Generation Years:
2002-2007
Codes
Vin Drivetrain Code:
H (for AWD)
👋 Introduction
Market Position
Performance Segment:
Compact Performance Sedan/Wagon
Rally Heritage:
Directly influenced by Subaru's World Rally Championship (WRC) success
Competitive Analysis
Key Competitors:
Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf R
Key Features
Drivetrain Philosophy:
Symmetrical All-Wheel Drive (AWD) system with Driver Controlled Center Differential (DCCD)
Engine Philosophy:
Performance-tuned turbocharged Boxer engine
Suspension Tuning:
Performance-oriented suspension setup for enhanced handling
Braking System:
Upgraded Brembo braking system for superior stopping power
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete vehicle service and repair
Engine Coverage:
All engines (specifically EJ257 for WRX STI)
Drivetrain Coverage:
All-Wheel Drive (AWD) system, differentials, transmission
Body Coverage:
Exterior panels, interior trim, chassis components
Electrical Coverage:
Wiring diagrams, component testing, ECU diagnostics
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Official Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
File Type:
Digital (Searchable PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine teardown, assembly, cylinder head, pistons, crankshaft, lubrication, cooling
Engine Management:
Fuel injection, ignition system, emissions control, ECU diagnostics, sensors
Transmission:
6-speed manual transmission (TY756VW4CA), clutch system, driveline components
Suspension:
Front struts, rear multi-link, springs, shocks, anti-roll bars, alignment procedures
Brakes:
Front Brembo 4-piston calipers, rear 2-piston calipers, ABS system, brake fluid
Steering:
Power assisted rack and pinion, steering column
Electrical System:
Starting and charging system, lighting, instrumentation, audio system, power windows, airbags
HVAC:
Air conditioning, heating, ventilation, refrigerant handling
Body And Chassis:
Frame, body panels, doors, hood, trunk, glass, interior trim
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection
Troubleshooting:
Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, ECU relearning procedures
Specifications And Tolerances:
Torque specifications, measurement tolerances, clearances
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine/transmission rebuilds)
Diagnostic Capability:
Advanced diagnostic procedures, component-level testing
Wiring Detail:
Pinouts, wire colors, connector diagrams
📊 Manual Specifications
File Format
File Format Type:
PDF (Portable Document Format)
Searchability:
Text-searchable, allowing quick access to specific information
Printability:
Printable pages for workshop use
Digital Features:
Hyperlinked sections for easy navigation (typical for professional PDFs)
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally-opposed turbocharged Boxer 4-cylinder
Displacement:
2.0 Liters (1994 cc)
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio:
8.4:1
Valve Train:
DOHC, 16 valves (4 valves per cylinder)
Performance
Horsepower:
300 hp @ 6000 rpm (SAE Net)
Torque:
290 lb-ft @ 4000 rpm (SAE Net)
Fuel System
Fuel Delivery:
Sequential multi-port fuel injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Turbocharger:
IHI VF30 (or similar, depending on market)
Intercooler:
Top-mounted air-to-air intercooler
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Transmission Model:
TY756VW4CA
Optional
Optional Transmission:
N/A (6-speed manual was standard on WRX STI)
Features
Dccd:
Driver Controlled Center Differential (DCCD) with automatic and manual modes
Differential Type:
Front: Helical LSD; Rear: Active Torque Split DCCD with Viscous LSD
📐 Dimensions
Exterior
Length:
4415 mm (173.8 inches)
Width:
1770 mm (69.7 inches)
Height:
1440 mm (56.7 inches)
Wheelbase:
2625 mm (103.3 inches)
Front Track:
1515 mm (59.6 inches)
Rear Track:
1505 mm (59.3 inches)
Weights
Curb Weight:
Approx. 1460 kg (3219 lbs)
Gross Vehicle Weight Rating:
Approx. 1900 kg (4189 lbs)
Cargo
Trunk Volume:
Approx. 0.33 m³ (11.8 cu ft) (Sedan)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
4/5 Stars (Driver/Passenger)
NHTSA Side Impact Test:
4/5 Stars (Front/Rear Passenger)
IIHS Moderate Overlap Front:
Good
Active Features
ABS:
4-wheel Anti-lock Braking System (ABS)
E Brake Force Distribution:
Electronic Brake-force Distribution (EBD)
Traction Control:
Standard Traction Control System (TCS)
Passive Features
Airbags:
Front driver and passenger airbags, front side-impact airbags
Seatbelts:
3-point seatbelts with pretensioners and load limiters
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system
💡 Technology Features
Infotainment
Head Unit:
Factory-installed CD player with AM/FM radio. Higher trims may have premium audio systems.
Speaker System:
Standard 4-speaker or optional 6-speaker audio system (e.g., Clarion).
Driver Assistance
Cruise Control:
Standard electronic cruise control
Anti Theft System:
Factory immobilizer and alarm system
Connectivity
Auxiliary Input:
Optional or aftermarket auxiliary input for audio devices
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions), or 7,500 miles or 12 months (normal conditions)
Air Filter Replacement Interval:
Every 15,000-30,000 miles, or as needed based on inspection
Cabin Air Filter Replacement Interval:
Every 15,000-30,000 miles, or annually
Spark Plug Replacement Interval:
Every 30,000-60,000 miles (depending on plug type - iridium recommended)
Timing Belt Replacement Interval:
Not applicable (uses a timing chain)
Fluid Specifications
Engine Oil Type:
5W-30 Synthetic (API SN or higher recommended)
Engine Oil Capacity:
4.5 US quarts (4.3 L) with filter
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant
Coolant Capacity:
Approx. 7.5 US quarts (7.1 L)
Transmission Fluid Type:
API GL-4 Gear Oil (e.g., Subaru Extra-S or equivalent high-quality 75W-90)
Transmission Fluid Capacity:
Approx. 3.0 US quarts (2.8 L)
Rear Differential Fluid Type:
API GL-5 Gear Oil (75W-90)
Rear Differential Fluid Capacity:
Approx. 0.9 US quarts (0.85 L)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid Type:
Subaru Automatic Transmission Fluid (ATF) - Type WS (or equivalent)
Known Issues
Head Gasket Failures:
While less common than earlier models, early GDB EJ25 engines can still be susceptible to head gasket failure, especially if not maintained or if modified.
Piston Ringland Failure:
Can occur with aggressive tuning or detonation. Regular use of premium fuel and proper engine management is crucial.
Clutch Wear:
High-performance nature of the STI can lead to faster clutch wear, especially with aggressive driving.
Turbocharger Wear:
The IHI VF30 turbo can develop wear over time, leading to reduced boost pressure or failure.
Oil Consumption:
Some EJ25 engines exhibit higher than average oil consumption, necessitating regular oil level checks.
📚 Vehicle History
Brand Heritage
Subaru Rally Heritage:
Subaru's long-standing success and association with the World Rally Championship (WRC) heavily influenced the Impreza WRX STI lineage.
Model Evolution
Gc8 To Gdb Transition:
The 2004 model marks the transition to the second generation (GDB) chassis, offering significant upgrades in styling, technology, and performance over the previous GC8 generation.
Sti Evolution:
The STI (Subaru Tecnica International) variant represents the pinnacle of the Impreza line, featuring enhanced engines, transmissions, suspensions, and braking systems derived from rally technology.
Production
Production Period:
Second generation (GDB) produced from 2002 to 2007
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Impreza WRX (non-STI) was frequently recognized on Car and Driver's 10Best lists during this era, highlighting the model's performance credentials.
Ratings
Sport Compact Of The Year:
The WRX STI often received 'Sport Compact of the Year' awards from various automotive publications.
Certifications
Engine Certification:
Meets EPA and CARB emissions standards for the model year
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